Molding method and molding apparatus

ABSTRACT

A molding method includes drawing cross-section elements of a three-dimensional object as a molding target on a drawing surface of a drawing stand with a liquid whose curing is precipitated by receiving activation energy as cross-section patterns; applying the activation energy to the liquid configuring the cross-section patterns in a state in which the cross-section patterns is pinched between the drawing stand and a molding stand; and detaching the cross-section patterns after being applied with the activation energy from the drawing stand and transferring the cross-section patterns to the molding stand side, wherein the drawing surface has a liquid repellent area that is an area representing liquid repellency for the liquid and a lyophilic area that is independently formed in an island shape within the liquid repellent area and is an area representing lyophillicity stronger than that of the liquid repellent area for the liquid.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional patent application of U.S. application Ser. No.13/037,587 filed Mar. 1, 2011, which claims priority to Japanese PatentApplication No. 2010-045000, filed Mar. 2, 2010, all of which areexpressly incorporated by reference herein in their entireties.

BACKGROUND

1. Technical Field

The present invention relates to a molding method, a molding apparatus,and the like.

2. Related Art

Generally, as a method of molding a three-dimensional object (a moldingmethod), a lamination method is known (for example, see JP-A-10-34752).

According to the lamination method, generally, a three-dimensionalobject is molded by sequentially laminating cross-section patterns andforming a plurality of cross-section elements that define the outershape of the three-dimensional object.

In JP-A-10-34752 described above, as a method of forming thecross-section pattern, the following method is disclosed.

In this method, first, a cross-section element is drawn on a temporarytable, which is coated with fluoride, as a cross-section pattern with anultraviolet curable resin. Next, the cross-section pattern is irradiatedwith ultraviolet rays (ultraviolet light) in the state in which thecross-section pattern is pinched by the temporary table and a moldingtable. Next, the cross-section pattern and the temporary table areseparated from each other. In this method, when the cross-sectionpattern is irradiated with the ultraviolet rays, the cross-sectionpattern is cured in a state of being bonded to the molding table. Inaddition, since the temporary table is coated with fluoride, thecross-section pattern can be easily detached from the temporary table.According to this method, the cross-section pattern can be easilytransferred onto the molding table.

However, according to the method disclosed in JP-A-10-34752, since thetemporary table is coated with fluoride, it may be difficult for theultraviolet curable resin in a liquid state to spread on the temporarytable depending on the viscosity of the ultraviolet curable resin. Inthis state, it is difficult to increase the precision of thecross-section pattern.

In other words, according to the general molding method, there is aproblem in that it is difficult to increase the precision of a moldingobject.

SUMMARY

An advantage of some aspects of the invention is to solve at least apart of the problems described above, and the invention can beimplemented in the following forms or application examples.

Application Example 1

According to this application example, there is provided a moldingmethod including: dividing a three-dimensional object as a moldingtarget into a plurality of cross-section elements and drawing thecross-section elements as cross-section patterns on a drawing surface ofa drawing stand having the drawing surface with a liquid whose curing isprecipitated by receiving activation energy; applying the activationenergy to the liquid configuring the cross-section patterns in a statein which the cross-section patterns drawn on the drawing stand ispinched between the drawing stand and a molding stand; and detaching thecross-section patterns after being applied with the activation energyfrom the drawing stand and transferring the cross-section patterns tothe molding stand side. In the dividing of a three-dimensional objectand the drawing of the cross-section elements, the cross-sectionpatterns are drawn on the drawing surface that has a liquid repellentarea that is an area representing liquid repellency for the liquid and alyophilic area that is independently formed in an island shape withinthe liquid repellent area and is an area representing lyophillicitystronger than that of the liquid repellent area for the liquid.

The molding method according to this application example includes thedividing of a three-dimensional object and drawing of cross-sectionelements, the applying of activation energy, and the detaching of thecross-section patterns. In the dividing of a three-dimensional objectand drawing of the cross-section elements, a three-dimensional object asa molding target is divided into a plurality of cross-section elements,and the cross-section elements are drawn on a drawing surface of adrawing stand with a liquid as cross-section patterns. Curing of theliquid is precipitated by receiving activation energy.

In the applying of the activation energy, the activation energy isapplied to the liquid configuring the cross-section patterns in a statein which the cross-section patterns drawn on the drawing stand ispinched between the drawing stand and a molding stand. Accordingly,curing of the cross-section patterns pinched between the drawing standand the molding stand is precipitated.

In the detaching of the cross-section patterns, the cross-sectionpatterns are detached from the drawing stand, and the cross-sectionpatterns are transferred to the molding stand side.

Accordingly, a plurality of the cross-section patterns can be laminatedon the molding stand side. As a result, the three-dimensional object asa molding target can be formed on the molding stand.

According to this molding method, in the dividing of a three-dimensionalobject and drawing of the cross-section elements, the cross-sectionpatterns are drawn on the drawing surface having a liquid repellent areaand a lyophilic area. The liquid repellent area is an area representingliquid repellency for the liquid. The lyophilic area is an arearepresenting lyophillicity stronger than that of the liquid repellentarea for the liquid. The lyophilic area is independently formed in anisland shape within the liquid repellent area.

Since the drawing surface has the liquid repellent area, in thedetaching of the cross-section patterns, the cross-section patterns canbe easily detached from the drawing stand. In addition, since thelyophilic area is independently formed in an island shape within theliquid repellent area, when the drawing surface is coated with theliquid, the liquid can be easily maintained in the lyophilic area.Accordingly, the precision of the cross-section patterns at a time whenthe cross-section patterns are drawn in the liquid repellent area withthe liquid can be easily increased. As a result, the precision of thethree-dimensional object as a molding target can be easily increased.

Application Example 2

In the above-described molding method, the liquid has photo curabilitythat is a property of being precipitated to be cured by receivingirradiation of light, and, in the applying of the activation energy, theliquid is irradiated with the light.

According to this application example, the liquid has photo curability.The photo curability is a property of being precipitated to be cured byreceiving irradiation of light. In the applying of the activationenergy, the liquid is irradiated with light. Accordingly, curing of theliquid configuring the cross-section patterns can be precipitated.

Application Example 3

In the above-described molding method, in the dividing of athree-dimensional object and the drawing of the cross-section elements,the cross-section patterns are drawn on the drawing surface by ejectingthe liquid to the drawing stand using an ink jet method.

In this application example, in the dividing of a three-dimensionalobject and drawing of cross-section elements, the cross-section patternsare drawn on the drawing surface by ejecting the liquid to the drawingstand using an ink jet method. Accordingly, the cross-section patternscan be drawn on the drawing surface.

Application Example 4

According to this application example, there is provided a moldingapparatus including: an ejection head that ejects a liquid whose curingis precipitated by receiving activation energy; a drawing stand that hasa drawing surface that is a surface on which cross-section patterns of athree-dimensional object as a molding target are drawn with the liquidejected from the ejection head; an energy applying device that appliesactivation energy to the liquid adhering to the drawing surface; and amolding stand on which the cross-sectional patterns after being appliedwith the activation energy are transferred from the drawing stand. Onthe drawing surface, a liquid repellent area that is an arearepresenting liquid repellency for the liquid and a lyophilic area thatis independently formed in an island shape within the liquid repellentarea and is an area representing lyophillicity stronger than that of theliquid repellent area for the liquid are arranged.

The molding apparatus of this application example includes: an ejectionhead; a drawing stand; an energy applying device; and a molding stand.

The ejection head ejects a liquid whose curing is precipitated byreceiving activation energy.

The drawing stand has a drawing surface. The drawing surface is asurface on which cross-section patterns of a three-dimensional object asa molding target are drawn with the liquid ejected from the ejectionhead.

The energy applying device applies activation energy to the liquidadhering to the drawing surface. The cross-section patterns aretransferred to the molding stand from the drawing stand.

In this molding apparatus, a liquid repellent area and a lyophilic areaare disposed on the drawing surface. The liquid repellent area is anarea representing liquid repellency for the liquid. The lyophilic areais an area representing lyophillicity stronger than that of the liquidrepellent area for the liquid. The lyophilic area is independentlyformed in an island shape within the liquid repellent area.

Since the liquid repellent area is arranged on the drawing surface inthe molding apparatus, the cross-section patterns can be easily detachedfrom the drawing stand. In addition, since the lyophilic area isindependently formed in an island shape within the liquid repellentarea, when the drawing surface is coated with the liquid, the liquid canbe easily maintained in the lyophilic area. Accordingly, the precisionof the cross-section patterns at a time when the cross-section patternsare drawn in the liquid repellent area with the liquid can be easilyincreased. As a result, the precision of the three-dimensional object asa molding target can be easily increased.

Application Example 5

In the above-described molding apparatus, the liquid has photocurability that is a property of being precipitated to be cured byreceiving irradiation of light, and the energy applying deviceirradiates the liquid with the light.

According to this application example, the liquid has photo curability.The photo curability is a property of being precipitated to be cured byreceiving irradiation of light. The energy applying device irradiatesthe liquid with light. Accordingly, curing of the liquid configuring thecross-section patterns can be precipitated.

Application Example 6

In the above-described molding apparatus, the ejection head ejects theliquid in a liquid droplet state.

In this application example, since the ejection head ejects the liquidin a liquid droplet state, the cross-section patterns can be drawn withthe liquid.

Application Example 7

In the above-described molding apparatus, a plurality of the lyophilicareas is disposed within the liquid repellent area, the plurality of thelyophilic areas configures a plurality of first arrangements arranged ina first direction in the plan view, and the plurality of the firstarrangements is aligned in a second direction that is a directionintersecting the first direction in the plan view.

In this application example, a plurality of the lyophilic areas isdisposed within the liquid repellent area. The plurality of thelyophilic areas configures a plurality of first arrangements arranged ina first direction in the plan view. The plurality of the firstarrangements is aligned in a second direction that is a directionintersecting the first direction in the plan view.

According to the above-described configuration, since the plurality ofthe lyophilic areas is regularly scattered, the precision of thecross-section patterns can be easily increased while the detachabilityof the cross-section patterns from the drawing stand is maintained.

Application Example 8

In the above-described molding apparatus, a plurality of the lyophilicareas is disposed within the liquid repellent area, the plurality of thelyophilic areas configures a plurality of first arrangements arranged ina first direction in the plan view, and the plurality of the firstarrangements is aligned in a zigzag pattern in a second direction thatis a direction intersecting the first direction in the plan view.

In this application example, a plurality of the lyophilic areas isdisposed within the liquid repellent area. The plurality of thelyophilic areas configures a plurality of first arrangements arranged ina first direction in the plan view. The plurality of the firstarrangements is aligned in a zigzag pattern in a second direction thatis a direction intersecting the first direction in the plan view.

According to the above-described configuration, since the plurality ofthe lyophilic areas is regularly scattered, the precision of thecross-section patterns can be easily increased while the detachabilityof the cross-section patterns from the drawing stand is maintained.

Application Example 9

In the above-described molding apparatus, a plurality of the lyophilicareas is disposed within the liquid repellent area, and the plurality ofthe lyophilic areas configures a spire using a Fibonacci sequence.

In this application example, a plurality of the lyophilic areas isdisposed within the liquid repellent area. The plurality of thelyophilic areas configures a spire using a Fibonacci sequence.

According to the above-described configuration, since the plurality ofthe lyophilic areas is scattered, the precision of the cross-sectionpatterns can be easily increased while the detachability of thecross-section patterns from the drawing stand is maintained.

In addition, according to this molding apparatus, in a two-dimensionalcoordinate system in the plan view, the linear regularity of theplurality of the lyophilic areas can be easily resolved. As a result,the precision of the cross-section patterns can be easily increased.

Application Example 10

In the above-described molding apparatus, the lyophilic areas protrudefrom the liquid repellent area.

Application Example 11

In the above-described molding apparatus, a gap size between thelyophilic areas adjacent to each other is a distance equal to or lessthan 1.25 times an outer diameter of the liquid droplet that is ejectedfrom the ejection head.

In this application example, the gap size between the lyophilic areasadjacent to each other is a distance equal to or less than 1.25 timesthe outer diameter of the liquid droplet that is ejected from theejection head. Accordingly, when the liquid droplet ejected from theejection head lands on a space between the lyophilic areas adjacent toeach other, a dot formed by the landed liquid droplet can be easilymaintained in the gap between two lyophilic areas adjacent to eachother.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described with reference to the accompanyingdrawings, wherein like numbers reference like elements.

FIG. 1 is a perspective view showing the schematic configuration of amolding system according to this embodiment.

FIG. 2 is a perspective view showing the schematic configuration of amolding apparatus according to this embodiment.

FIG. 3 is a front view when a carriage is seen in the direction of arrowA shown in FIG. 2.

FIG. 4 is a bottom view of an ejection head according to thisembodiment.

FIG. 5 is a cross-section view taken along line B-B shown in FIG. 3.

FIG. 6 is a perspective view showing the state in which a substratetable and an exposure device overlap each other in a molding apparatusaccording to this embodiment.

FIG. 7 is a perspective view showing a light source of an exposuredevice according to this embodiment.

FIG. 8 is a block diagram showing the schematic diagram of a moldingsystem according to this embodiment.

FIG. 9 is a diagram illustrating a plurality of cross-section elementsaccording to this embodiment.

FIG. 10 is a diagram showing the flow of a molding method according tothis embodiment.

FIG. 11 is a diagram showing the flow of a drawing process according tothis embodiment.

FIG. 12 is a diagram showing the flow of a transfer process according tothis embodiment.

FIG. 13 is a diagram illustrating a gap between a substrate and atransfer plate in a transfer process according to this embodiment.

FIG. 14 is a diagram illustrating a cross-section pattern transferred toa transfer plate in a transfer process according to this embodiment.

FIG. 15 is a diagram illustrating a three-dimensional object that ismolded by a molding apparatus according to this embodiment.

FIG. 16 is an enlarged plan view of a part of a drawing surfaceaccording to this embodiment.

FIG. 17 is a diagram illustrating a method of forming a liquid repellentarea and lyophilic areas on a substrate according to a first embodiment.

FIG. 18 is a cross-sectional view of a substrate according to a secondembodiment, taken along line D-D shown in FIG. 16.

FIGS. 19A, 19B, and 19C are diagrams illustrating a method ofmanufacturing a substrate according to the second embodiment.

FIG. 20 is a plan view showing another example of an arrangement of aplurality of lyophilic areas according to each of the first and secondembodiments.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Embodiments of the invention will be described with reference to theaccompanying drawings. In the drawings, in order to size eachconfiguration to be recognizable, the scales of the configuration andthe members thereof may be differently set.

A molding system 1 according to this embodiment, as shown in FIG. 1,includes a computer 3 and a molding apparatus 5.

The computer 3 performs a calculation process for extracting a pluralityof cross-section elements from shape data of a three-dimensional object7 that is a molding target. In addition, the computer 3 outputs data ofthe extracted cross-section elements (hereinafter, referred to ascross-section data) to the molding apparatus 5.

The molding apparatus 5 molds the three-dimensional object 7 by drawingcross-section patterns corresponding to the cross-section elements basedon the cross-section data output from the computer 3 and sequentiallylaminating the drawn cross-section patterns.

The molding apparatus 5 according to this embodiment, as shown in FIG. 2that is a perspective view representing the schematic configurationthereof, includes a substrate transporting device 11, a carriage 12, acarriage transporting device 13, an exposure device 15, and a transferdevice 17.

In the carriage 12, a head unit 14 is disposed.

In the molding apparatus 5, a desired pattern can be drawn on a drawingsurface 18 of a substrate W by ejecting a liquid as a liquid dropletfrom the head unit 14 while changing a relative position between thehead unit 14 and the substrate W in the plan view. In this embodiment,the molding apparatus 5 draws a cross-section pattern on the substrate Wbased on the cross-section data that is output from the computer 3 (FIG.1).

In the figure, the Y direction represents the movement direction of thesubstrate W, and the X direction represents a direction perpendicular tothe Y direction in the plan view. In addition, a direction that isperpendicular to an XY plane defined by the X direction and the Ydirection is defined as the Z direction.

The substrate transporting device 11, as shown in FIG. 2, includes asurface plate 21, a guide rail 23 a, a guide rail 23 b, and a table 25.

The surface plate 21 is configured by a material having a smallcoefficient of thermal expansion such as a stone and is installed so asto expand in the Y direction. The guide rail 23 a and the guide rail 23b are installed on the top face 21 a of the surface plate 21. The guiderail 23 a and the guide rail 23 b extend in the Y direction. The guiderail 23 a and the guide rail 23 b are parallel to each other with a gaptherebetween being open toward the X direction.

The table 25 is disposed in a state of facing the top face 21 a of thesurface plate 21 with the guide rail 23 a and the guide rail 23 binterposed therebetween. The table 25 is mounted on the guide rail 23 aand the guide rail 23 b in a state of being floated from the surfaceplate 21. The table 25 includes a mounting surface 25 a on which thesubstrate W is mounted. The mounting surface 25 a faces the side (upperside) opposite to the surface plate 21 side. The table 25 is guidedalong the Y direction by the guide rail 23 a and the guide rail 23 b andis configured so as to reciprocate along the Y direction on the surfaceplate 21.

The table 25 is configured so as to be able to reciprocate by using amovement mechanism and a power source, which are not shown in thefigure, in the Y direction. As the movement mechanism, for example, amechanism acquired by combining a ball screw and a ball nut, a linearguide mechanism, or the like can be employed. In this embodiment, as thepower source used for moving the table 25 in the Y direction, asubstrate transporting motor to be described later is used. As thesubstrate transporting motor, various motors such as a stepping motor, aservo motor, and a linear motor can be used.

The power is transferred from the substrate transporting motor to thetable 25 through the movement mechanism. Accordingly, the table 25 canreciprocate along the guide rail 23 a and the guide rail 23 b, that is,along the Y direction. In other words, the substrate transporting device11 can allow the substrate W mounted on the mounting surface 25 a of thetable 25 to reciprocate in the Y direction. In addition, the substratetransporting device 11 includes a table position detecting device to bedescribed later. The table position detecting device detects theposition of the table 25 in the Y direction. Based on a result of thedetection operation of the table position detecting device, the positionof the substrate W in the Y direction can be acquired.

The head unit 14, as shown in FIG. 3 as a front view acquired when thecarriage 12 is seen in the direction of arrow A shown in FIG. 2,includes a head plate 31 and an ejection head 33. The ejection head 33,as shown in FIG. 4 as a bottom view, includes a nozzle surface 35. Onthe nozzle surface 35, a plurality of nozzles 37 is formed. In FIG. 4,in order to represent the nozzles 37 to be easily understood, thenozzles 37 are exaggerated, and the number of the nozzles 37 isdecreased. In the ejection head 33, the plurality of the nozzles 37forms twelve nozzle rows 39 each arranged in the Y direction. The twelvenozzle rows 39 are parallel to each other in a state in which gapstherebetween are open in the X direction. In each nozzle row 39, theplurality of the nozzles 37 is formed with a predetermined nozzle gap Pin the Y direction.

Hereinafter, when each of the twelve nozzle rows 39 is to be identified,notations of a nozzle row 39 a, a nozzle row 39 b, a nozzle row 39 c, anozzle row 39 d, a nozzle row 39 e, a nozzle row 39 f, a nozzle row 39g, a nozzle row 39 h, a nozzle row 39 i, a nozzle row 39 j, a nozzle row39 k, and a nozzle row 39 m are used.

In the ejection head 33, the nozzle row 39 a and nozzle row 39 b aremisaligned from each other by a distance P/2 in the Y direction. Thenozzle row 39 c and nozzle row 39 d are misaligned from each other by adistance P/2 in the Y direction. Similarly, the nozzle row 39 e andnozzle row 39 f are misaligned from each other by a distance P/2 in theY direction, and the nozzle row 39 g and nozzle row 39 h are misalignedfrom each other by a distance P/2 in the Y direction. Similarly, thenozzle row 39 i and nozzle row 39 j are misaligned from each other by adistance P/2 in the Y direction, and the nozzle row 39 k and nozzle row39 m are misaligned from each other by a distance P/2 in the Ydirection.

The ejection head 33 as shown in FIG. 5 as a cross-sectional view takenalong line B-B shown in FIG. 3 includes a nozzle plate 46, a cavityplate 47, a vibration plate 48, and a plurality of piezoelectricelements 49.

The nozzle plate 46 includes the nozzle surface 35. The plurality of thenozzles 37 is disposed on the nozzle plate 46.

The cavity plate 47 is disposed on a face of the nozzle plate 46 that islocated on the side opposite to the nozzle surface 35. In the cavityplate 47, a plurality of cavities 51 is formed. The cavities 51 aredisposed in correspondence with the nozzles 37 and respectivelycommunicate with the corresponding nozzles 37. A functional liquid 53 issupplied to each cavity 51 from a tank not shown in the figure.

The vibration plate 48 is disposed on a face of the cavity plate 47 thatis located on a side opposite to the nozzle plate 46 side. The vibrationplate 48 vibrates (vertically vibrates) in the Z direction, therebyincreasing or decreasing the volume inside the cavity 51.

The plurality of piezoelectric elements 49 is disposed on a face of thevibration plate 48 that is located on a side opposite to the cavityplate 47 side. The piezoelectric elements 49 are disposed incorrespondence with the cavities 51 and face the cavities 51 with thevibration plate 48 being interposed therebetween. Each piezoelectricelement 49 expands based on a driving signal. Accordingly, the vibrationplate 48 decreases the volume inside the cavity 51. At this time,pressure is applied to the functional liquid 53 inside the cavity 51. Asa result, the functional liquid 53 is ejected as liquid droplets 55 fromthe nozzles 37. A method of ejecting the liquid droplets 55 using theejection head 33 is one of the ink jet methods. The ink jet method isone of the coating methods.

The ejection head 33 having the above-described configuration, as shownin FIG. 3, is supported by the head plate 31 in the state in which thenozzle surface 35 protrudes from the head plate 31.

The carriage 12, as shown in FIG. 3, supports the head unit 14. Here,the head unit 14 is supported by the carriage 12 in the state in whichthe nozzle surface 35 faces the lower side in the Z direction.

In this embodiment, the vertical-vibration-type piezoelectric element 49is used. However, a pressing unit that is used for applying pressure tothe functional liquid 53 is not limited thereto. For example, abending-transformation-type piezoelectric element that is formed bylaminating a lower electrode, a piezoelectric layer, and an upperelectrode may be used. In addition, as the pressing unit, a so-calledelectrostatic-type actuator that ejects liquid droplets from nozzles bygenerating static electricity between a vibration plate and an electrodeand transforming the vibration plate depending on an electrostatic forcemay be used. Furthermore, a configuration in which bubbles are generatedinside nozzles using a heating body and pressure is applied to thefunctional liquid using the bubbles may be used.

In this embodiment, as the functional liquid 53, a liquid whose curingis precipitated by receiving activation energy is used. In addition, inthis embodiment, light is used as the activation energy. In other words,in this embodiment, the functional liquid 53 has a photo-curableproperty in which curing of the functional liquid 53 is precipitated byreceiving irradiation of light. In this embodiment, as light that isused for precipitating the curing of the functional liquid 53, anultraviolet light is used.

As the functional liquid 53 whose curing is precipitated by receivingirradiation of light, a resin material to which a photo-curing agent isadded or the like may be used. As the resin material, for example, anacryl-based or epoxy-based resin material or the like may be used. Asthe photo-curing agent, for example, a radical-polymerization-typephotopolymerization initiator, a cation-polymerization-typephotopolymerization initiator, or the like may be used.

Examples of the radical-polymerization-type photopolymerizationinitiator include isobutyl benzoin ether, isopropyl benzoin ether,benzoin ethyl ether, benzoin methyl ether, benzyl, hydroxy cyclohexylphenyl ketone, diethoxy acetophenon, chlorothioxanthone, isopropylthioxanthone, and the like.

In addition, examples of the cation-polymerization-typephotopolymerization initiator include allyl sulfonium salt derivatives,allyl iodonium salt derivatives, diazonium salt derivatives, andtriazine-based initiators.

By adding a functional material such as a coloring element includingpigments, dyes, or the like, a lyophilic or liquid-repellent surfacereforming material, or the like to the functional liquid 53 having theabove-described configuration, the functional liquid 53 having a uniquefunction can be generated.

The functional liquid 53 containing a coloring element such as a pigmentor a dye can represent a cross-section pattern, which is drawn on thesubstrate W, in colors. Hereinafter, a functional liquid 53 thatcontains a coloring element such as pigment, dye, or the like isreferred to as a color coating material.

In addition, for example, by using a resin material having opticaltransparency as the resin material as a component of the functionalliquid 53, a functional liquid 53 having optical transparency can beformed. Hereinafter, the functional liquid 53 having opticaltransparency is referred to as a translucent coating material. Thefunctional liquid 53 having the optical transparency, for example, maybe used as clear ink.

As the application of clear ink, for example, an application as anovercoat layer with which an image is coated or an application as a baselayer before formation of an image, or the like may be considered.Hereinafter, the functional liquid 53 that is applied as the base layeris referred to as a base coating material.

As the base coating material, not only a translucent coating materialbut a functional liquid 53 acquired by adding various pigments to atranslucent coating material may be used.

In this embodiment, as the functional liquid 53, five types of the colorcoating materials having different colors and one type of thetranslucent coating material are used. The different colors of thefive-types of the color coating materials are yellow (Y), magenta (M),cyan (C), black (K), and white (W).

Hereinafter, when the five types of the functional liquid 53 areindividually identified by their colors, notations of a functionalliquid 53Y, a functional liquid 53M, a functional liquid 53C, afunctional liquid 53K, and a functional liquid 53W are used. Inaddition, for a functional liquid 53 corresponding to a translucentcoating material, a notation of a functional liquid 53T is used. In thisembodiment, since the color coating materials (the functional liquids53) having five different colors are used, color representation of athree-dimensional object 7 is realized. In addition, since thetranslucent coating material is used in this embodiment, athree-dimensional object 7 having light transparency can be molded.

In the ejection head 33, twelve nozzle rows 39 (FIG. 4) described aboveare divided by the colors of the functional liquids 53. In thisembodiment, the nozzles 37 belonging to the nozzle row 39 a and thenozzle row 39 b eject the functional liquids 53K as the liquid droplets55. The nozzles 37 belonging to the nozzle row 39 c and the nozzle row39 d eject the functional liquids 53C as the liquid droplets 55. Inaddition, the nozzles 37 belonging to the nozzle row 39 e and the nozzlerow 39 f eject the functional liquids 53M as the liquid droplets 55. Thenozzles 37 belonging to the nozzle row 39 g and the nozzle row 39 heject the functional liquids 53Y as the liquid droplets 55. The nozzles37 belonging to the nozzle row 39 i and the nozzle row 39 j eject thefunctional liquids 53W as the liquid droplets 55. The nozzles 37belonging to the nozzle row 39 k and the nozzle row 39 m eject thefunctional liquids 53T as the liquid droplets 55.

The carriage transporting device 13, as shown in FIG. 2, includes amount 61, a guide rail 63, and a carriage position detecting device 65.

The mount 61 extends in the X direction and passes over the substratetransporting device 11 in the X direction. The mount 61 faces thesubstrate transporting device 11 on a side opposite to the surface plate21 side of the table 25. The mount 61 is supported by a support post 67a and a support post 67 b. The support post 67 a and the support post 67b are disposed at opposite positions with the surface plate 21interposed therebetween in the X direction. The support post 67 a andthe support post 67 b protrude to the upper side in the Z directionrelative to the table 25. Accordingly, a gap is maintained between themount 61 and the table 25.

The guide rail 63 is disposed on the surface plate 21 side of the mount61. The guide rail 63 extends in the X direction and is disposed overthe width of the mount 61 in the X direction. The above-describedcarriage 12 is supported by the guide rail 63. In the state in which thecarriage 12 is supported by the guide rail 63, the nozzle surface 35 ofthe ejection head 33 faces the table 25 side in the Z direction. Thecarriage 12 is guided by the guide rail 63 in the X direction and issupported by the guide rail 63 in a state of being reciprocable in the Xdirection. In the plan view, in the state in which the carriage 12 andthe table 25 overlap each other, the nozzle surface 35 and the mountingsurface 25 a of the table 25 face each other with a gap therebetweenbeing maintained. The carriage position detecting device 65 is disposedbetween the mount 61 and the carriage 12 and extends in the X direction.The carriage position detecting device 65 detects the position of thecarriage 12 in the X direction.

The carriage 12 is configured so as to reciprocate in the X direction bya movement mechanism and a power source that are not shown in thefigure. As the movement mechanism, a mechanism acquired by combining aball screw and a ball nut, a linear guide mechanism, or the like can beused. In this embodiment, as the power source used for moving thecarriage 12 in the X direction, a carriage transporting motor to bedescribed later is used. As the carriage transporting motor, variousmotors such as a stepping motor, a servo motor, and a linear motor canbe used.

The power is transferred from the carriage transporting motor to thecarriage 12 through the movement mechanism. Accordingly, the carriage 12can reciprocate along the guide rail 63, that is, the X direction. Inother words, the carriage transporting device 13 can reciprocate thehead unit 14, which is supported by the carriage 12, in the X direction.

The exposure device 15 is a device that irradiates ultraviolet lightonto a cross-section pattern drawn on the substrate W. The exposuredevice 15 is disposed one end side of the surface plate 21 in the Ydirection. The height of the exposure device 15 in the Z direction issuppressed as being equal to or less than the height of the top face 21a of the surface plate 21.

The guide rail 23 a and the guide rail 23 b extend over the length ofthe exposure device 15 in the Y direction. The guide rail 23 a and theguide rail 23 b face each other in the X direction with the exposuredevice 15 interposed therebetween.

Accordingly, the table 25, as shown in FIG. 6, overlaps the exposuredevice 15 in the plan view.

The exposure device 15, as shown in FIG. 7, includes a light source 81.The light source 81 emits ultraviolet light. As the light source 81, forexample, a mercury lamp, a metal halide lamp, a xenon lamp, an excimerlamp, or the like can be used.

In this embodiment, the table 25 has optical transparency for theultraviolet light. Accordingly, in the state in which the table 25 andthe exposure device 15 overlap each other in the plan view, theultraviolet light emitted from the exposure device 15 can reach thesubstrate W that is mounted on the table 25. Examples of the material ofthe table 25 include glass, quartz, and the like.

The transfer device 17, as shown in FIG. 2, includes a support post 83,a transfer plate 85, and an elevation motor 87.

The support post 83 is disposed in a position overlapping the exposuredevice 15 in the plan view. The support post 83 passes over the surfaceplate 21 and the exposure device 15 in the X direction. In the state inwhich the table 25 and the exposure device 15 overlap each other in theplan view, a gap is maintained between the table 25 and the support post83.

The transfer plate 85 is disposed in a position overlapping the exposuredevice 15 in the plan view. The transfer plate 85 hangs at a beamportion 83 a of the support post 83 toward the lower side in the Zdirection. The transfer plate 85 is configured so as to be raised orlowered in the Z direction by an elevation mechanism not shown in thefigure. As the elevation mechanism, for example, a mechanism acquired bycombining a ball screw and a ball nut, a linear guide mechanism, or thelike can be used.

The elevation motor 87 generates power used for raising or lowering thetransfer plate 85 in the Z direction. The power is transferred from theelevation motor 87 to the transfer plate 85 through an elevationmechanism. Accordingly, the transfer plate 85 can be raised or loweredin the Z direction.

In addition, the transfer device 17 includes a transfer plate positiondetecting device to be described later. The transfer plate positiondetecting device detects the position of the transfer plate 85 in the Zdirection. The position of the transfer plate 85 in the Z direction canbe acquired based on a result of a detection operation of the transferplate position detecting device.

The molding apparatus 5, as shown in FIG. 8, includes a control unit 111that controls the operation of each configuration described above. Thecontrol unit 111 includes a CPU (Central Processing Unit) 113, a drivingcontrol section 115, and a memory section 117. The driving controlsection 115 and the memory section 117 are connected to the CPU 113through a bus 119.

In addition, the molding apparatus 5 includes a carriage transportingmotor 121, a substrate transporting motor 123, a table positiondetecting device 125, and a transfer plate position detecting device127. The carriage transporting motor 121, the substrate transportingmotor 123, and the elevation motor 87 are connected to the control unit111 through an input/output interface 133 and the bus 119. In addition,the carriage position detecting device 65, the table position detectingdevice 125, and the transfer plate position detecting device 127 areconnected to the control unit 111 through the input/output interface 133and the bus 119.

The carriage transporting motor 121 generates power that is used fordriving the carriage 12. The substrate transporting motor 123 generatespower that is used for driving the table 25. The table positiondetecting device 125 detects the position of the table 25 in the Ydirection. The transfer plate position detecting device 127 detects theposition of the transfer plate 85 in the Z direction.

In addition, the ejection head 33 and exposure device 15 are connectedto the control unit 111 through the input/output interface 133 and thebus 119. Furthermore, the computer 3 is connected to the control unit111 through the input/output interface 133 and the bus 119.

The CPU 113 performs various calculation processes as a processor. Thedriving control section 115 controls to drive each configuration. Thememory section 117 includes a RAM (Random Access Memory), a ROM(Read-Only Memory), and the like. In the memory section 117, an area inwhich a software program 135 describing the control sequence of theoperation of the molding apparatus 5 is stored, a data expanding portion137 as an area in which various types of data are temporarily expanded,and the like are set. As the data expanded in the data expanding portion137, for example, there are cross-section data in which a cross-sectionpattern to be drawn is represented, program data used for a drawingprocess or the like, and the like.

The driving control section 115 includes a motor control portion 141, aposition detecting control portion 143, an ejection control portion 145,and an exposure control portion 147.

The motor control portion 141 respectively controls to drive thecarriage transporting motor 121, the substrate transporting motor 123,and the elevation motor 87 based on a command transmitted from the CPU113.

The position detecting control portion 143 respectively controls thecarriage position detecting device 65, the table position detectingdevice 125, and the transfer plate position detecting device 127 basedon a command transmitted from the CPU 113.

The position detecting control portion 143 allows the carriage positiondetecting device 65 to detect the position of the carriage 12 in the Xdirection and outputs a result of the detection to the CPU 113 based ona command transmitted from the CPU 113.

In addition, the position detecting control portion 143 allows the tableposition detecting device 125 to detect the position of the table 25 inthe Y direction and outputs a result of the detection to the CPU 113based on a command transmitted from the CPU 113.

The position detecting control portion 143 allows the transfer plateposition detecting device 127 to detect the position of the transferplate 85 in the Z direction and outputs a result of the detection to theCPU 113 based on a command transmitted from the CPU 113.

The ejection control portion 145 controls to drive the ejection head 33based on a command transmitted from the CPU 113.

The exposure control portion 147 individually controls the emissionstates of the light sources 81 of the exposure device 15 based on acommand transmitted from the CPU 113.

In the molding system 1 having the above-described configuration, aplurality of cross-section elements is extracted by the computer 3 fromthe shape data of the three-dimensional object 7 as a molding target.The three-dimensional object 7, as shown in FIG. 9, is configured by theplurality of cross-section elements 161. By sequentially overlapping theplurality of cross-section elements 161, the three-dimensional object 7as the molding target is configured. In other words, the plurality ofcross-sectional elements 161 is elements that configure the shape of thethree-dimensional object 7 as the molding target.

The computer 3 generates a plurality of sets of cross-section data basedon the plurality of the extracted cross-section elements 161. At thistime, one set of the cross-section data is generated from onecross-section element 161. The plurality of sets of cross-section datais output to the molding apparatus 5.

Here, the flow according to a molding method of this embodiment will bedescribed.

The molding method of this embodiment, as shown in FIG. 10, includes across-section data generating process S1, a drawing process S2, and atransfer process S3.

In the cross-section data generating process S1, as described above, aplurality of sets of cross-section data is generated from the shape dataof the three-dimensional object 7 as a molding target. In thecross-section data generating process S1, the cross-section data isgenerated by the computer 3.

In the drawing process S2, a cross-section pattern is drawn with thefunctional liquid 53 on a drawing surface 18 of the substrate W based onthe cross-section data. In the drawing process S2, the cross-sectionpattern is drawn by the molding apparatus 5. The drawing surface 18, asshown in FIG. 2, is a surface located on a side opposite to the table 25side and is a surface that faces the head unit 14 side. The drawingsurface 18 is a surface on which the cross-section pattern is drawn withthe functional liquid 53.

In the transfer process S3 after the drawing process S2, thecross-section pattern is transferred from the drawing surface 18 of thesubstrate W onto the transfer plate 85 while exposing the cross-sectionpattern by using the exposure device 15 for each drawn cross-sectionpattern.

The drawing process S2 and the transfer process S3 are repeatedlyperformed until there is no remaining cross-section data of a newcross-section pattern to be drawn. Accordingly, a three-dimensionalobject 7 is formed on the transfer plate 85.

In the drawing process S2, when the control unit 111 (FIG. 8) of themolding apparatus 5 acquires the cross-section data from the computer 3through the input/output interface 133 and the bus 119, a drawingprocess represented in FIG. 11 is performed for each cross-section databy the CPU 113.

Here, in the cross-section data, a cross-section pattern to be drawn isrepresented in a bit map pattern. The drawing of the cross-sectionpattern on the substrate W is performed by ejecting the liquid droplets55 from the ejection head 33 with a predetermined period whilerelatively reciprocating the ejection head 33 and the substrate W in thestate in which the ejection head 33 faces the substrate W.

In the drawing process, the CPU 113, first, outputs a carriage transportcommand to the motor control portion 141 (FIG. 8) in Step S21. At thistime, the motor control portion 141 moves the carriage 12 to a startposition of the forward path in a drawing area by controlling to drivethe carriage transporting motor 121. Here, the drawing area is an areain which a trajectory drawn by the table 25 shown in FIG. 2 in the Ydirection and a trajectory drawn by the ejection head 33 in the Xdirection overlap each other. The start position of the forward path isa position at which the forward path used for reciprocating the carriage12 starts. In this embodiment, the start position of the forward path islocated on the support post 67 a side of the surface plate 21 in the Xdirection. The start position of the forward path is located on theouter side of the surface plate 21 in the plan view. Next, in Step S22,the CPU 113 outputs a substrate transport command to the motor controlportion 141 (FIG. 8). At this time, the motor control portion 141 movesthe substrate W to the drawing area by controlling to drive thesubstrate transporting motor 123.

Next, the CPU 113 outputs a carriage scanning command to the motorcontrol portion 141 (FIG. 8) in Step S23. At this time, the motorcontrol portion 141 starts to reciprocate the carriage 12 by controllingto drive the carriage transporting motor 121.

Here, in the reciprocation of the carriage 12, the carriage 12reciprocates between the above-described start position of the forwardpath and a start position of a return path. In other words, a pathformed by starting from the start position of the forward path, turningover at the start position of the return path, and returning to thestart position of the forward path forms one operation of thereciprocation of the carriage 12. Accordingly, in this embodiment, apath toward the start position of the return path from the startposition of the forward path is the forward path of the carriage 12. Onthe other hand, a path toward the start position of the forward pathfrom the start position of the return path is the return path of thecarriage 12.

In addition, the start position of the return path is a position that isopposite to the start position of the forward path in the X directionwith respect to the surface plate 21 (FIG. 2). The start position of thereturn path is located on the outer side of the surface plate 21 in theplan view. Accordingly, the start position of the forward path and thestart position of the return path face each other with the surface plate21 being interposed therebetween in the X direction.

Next, the CPU 113 outputs an ejection command to the ejection controlportion 145 (FIG. 8) in Step S24. At this time, the ejection controlportion 145 ejects liquid droplets 55 from the nozzles 37 based on thecross-section data by controlling to drive the ejection head 33.Accordingly, drawing is performed in the forward path.

Next, the CPU 113 determines whether the position of the carriage 12arrives at the start position of the return path in Step S25. At thistime, when the position of the carriage 12 is determined to have arrivedat the start position of the return path (Yes), the process proceeds toStep S26. On the other hand, when the position of the carriage 12 isdetermined not to have arrived at the start position of the return path(No), the process is waited for until the position of the carriage 12arrives at the start position of the return path.

In Step S26, the CPU 113 outputs an ejection stop command to theejection control portion 145 (FIG. 8). At this time, the ejectioncontrol portion 145 stops the ejection of liquid droplets 55 from thenozzles 37 by stopping the driving of the ejection head 33. Accordingly,the drawing in the forward path is completed. Next, the CPU 113 outputsa linefeed command to the motor control portion 141 (FIG. 8) in StepS27. At this time, the motor control portion 141 moves a new area inwhich a pattern is to be drawn for the substrate W to the drawing areaby moving (line feeding) the substrate W in the Y direction bycontrolling to drive the substrate transporting motor 123.

Next, the CPU 113 outputs an ejection command to the ejection controlportion 145 (FIG. 8) in Step S28. At this time, the ejection controlportion 145 ejects liquid droplets 55 from the nozzles 37 based ondrawing data by controlling to drive the ejection head 33. Accordingly,the drawing in the return path is performed.

Next, the CPU 113 determines whether the position of the carriage 12arrives at the start position of the forward path in Step S29. At thistime, when the position of the carriage 12 is determined to have arrivedat the start position of the forward path (Yes), the process proceeds toStep S30. On the other hand, when the position of the carriage 12 isdetermined not to have arrived at the start position of the forward path(No), the process is waited for until the position of the carriage 12arrives at the start position of the forward path.

In Step S30, the CPU 113 outputs an ejection stop command to theejection control portion 145 (FIG. 8). At this time, the ejectioncontrol portion 145 stops the ejection of liquid droplets 55 from thenozzles 37 by stopping the driving of the ejection head 33. Accordingly,drawing in the return path is completed.

Next, in Step S31, the CPU 113 determines whether drawing of thecross-section pattern based on the cross-section data has completed. Atthis time, when the drawing of the cross-section pattern is determinedto have completed (Yes), the process is completed. On the other hand,when the drawing of the cross-section pattern is determined not to havecompleted (No), the process proceeds to Step S32.

In Step S32, the CPU 113 outputs a linefeed command to the motor controlportion 141 (FIG. 8) and then transfers the process to Step S24. At thistime, in Step S32, the motor control portion 141 moves a new area inwhich a pattern is to be drawn for the substrate W to the drawing areaby moving (line feeding) the substrate W in the Y direction bycontrolling to drive the substrate transporting motor 123.

In the transfer process S3, when the drawing process on the basis of thecross-section data is completed, a transfer process shown in FIG. 12 isstarted by the CPU 113. The transfer process is performed each time whenthe drawing process on the basis of the cross-section data is performed.

In the transfer process, the CPU 113, first, outputs a substratetransporting command to the motor control portion 141 (FIG. 8) in StepS51. At this time, the motor control portion 141 moves the substrate Wto an exposure area by controlling to drive the substrate transportingmotor 123. Here, the exposure area is an area overlapping the exposuredevice 15 in the plan view.

Next, in Step S52, the CPU 113 outputs a lowering command to the motorcontrol portion 141 (FIG. 8). At this time, the motor control portion141 lowers the transfer plate 85 by controlling to drive the elevationmotor 87.

Here, a case will be assumed in which n (here n is an integer equal toor greater than two) cross-section elements 161 are extracted in thecross-section data generating process S1 (FIG. 10). Hereinafter, whenthe n cross-section elements 161 are to be individually identified, asshown in FIG. 9, each of the n cross-section elements 161 is noted as across-section element 161 _(j) (here, j is an integer in the range of 1to n). Each of the n cross-section elements 161 has a thickness t. Bysequentially overlapping the first to n-th cross-section elements 161corresponding to the n cross-section elements 161 _(j), athree-dimensional object 7 having a thickness T as a molding target isconfigured. In other words, there is the relationship of “T=n×t” betweenthe thickness T and the thickness t.

In Step S52, the lowered position of the transfer plate 85 is controlledin accordance with numbers j from 1 to n of the n cross-section elements161. For example, for the first cross-section element 161, a gap betweenthe substrate W and the transfer plate 85, as shown in FIG. 13, iscontrolled to be a distance t. In other words, in Step S52, a gapbetween the substrate W and the transfer plate 85 is controlled to be adistance of “j×t” in accordance with the number j.

In Step S53 after Step S52, the CPU 113 outputs an exposure command tothe exposure control portion 147 (FIG. 8). At this time, the exposurecontrol portion 147 turns on the light source 81 of the exposure device15 by controlling to drive the light source 81 of the exposure device15.

Here, in this embodiment, the substrate W has optical transparency forultraviolet light. Accordingly, the ultraviolet light 163 emitted fromthe exposure device 15, as shown in FIG. 13, can arrive at thecross-section pattern 165 corresponding to the cross-section element 161through the table 25 and the substrate W. As the material of thesubstrate W, for example, glass, quartz, or the like can be used. Inaddition, as the ultraviolet light 163, ultraviolet light having awavelength equal to or longer than 200 nm can be used.

In FIG. 13, in order to represent the configuration to be more easilyunderstood, hatching is added to the cross-section element 161 (thecross-section pattern 165).

In Step S54 after Step S53, the CPU 113 outputs an exposure stop commandto the exposure control portion 147 (FIG. 8). At this time, the exposurecontrol portion 147 turns off the light source 81 of the exposure device15 by controlling to drive the light source 81 of the exposure device15.

Next, in Step S55, the CPU 113 outputs a raise command to the motorcontrol portion 141 (FIG. 8) and then completes the process. At thistime, in Step S55, the motor control portion 141 raises the transferplate 85 by controlling to drive the elevation motor 87. Accordingly,the cross-section pattern 165 for which exposure has been performed, asshown in FIG. 14, is transferred to the transfer plate 85. Hereinafter,when the cross-section pattern 165 is to be individually identified incorrespondence with a cross-section element 161, a notation ofcross-section pattern 165 _(j) is used.

By repeatedly performing the drawing process and the transfer processdescribed above up to the n-th cross-section element 161 _(n), ncross-section patterns 165 including a cross-section pattern 165 ₁ to across-section pattern 165 _(n), as shown in FIG. 15, sequentiallyoverlap one another on the transfer plate 85. Accordingly, thethree-dimensional object 7 is formed.

In this embodiment, a liquid repellent area that is an area representinga liquid repellency for the functional liquid 53 is disposed on thedrawing surface 18 of the substrate W. Accordingly, in the transferprocess S3, the cross-section pattern 165 can be easily detached fromthe substrate W.

The liquid repellency for the functional liquid 53 can be provided bycoating the drawing surface 18 with a material that represents a liquidrepellency for the functional liquid 53. Examples of the materialrepresenting the liquid repellency for the functional liquid 53 includematerials containing fluorine or a fluorine compound. As a coatingmethod, various methods such as a gas phase method in which the drawingsurface is exposed in a gas, a dip method in which the drawing surfaceis dipped into a liquid, a spray method in which a liquid is sprayed, aspin coat method in which a liquid extends, and the like can be used.

In this embodiment, the drawing surface 18 is coated with a materialthat contains a fluoroalkylsilane compound as one of the fluorinecompounds.

The liquid repellency for the functional liquid 53 can be provided alsoby performing a plasma process, for example, using a gas containingfluorine or a fluorine compound for the substrate W.

According to this embodiment, on the substrate W, as shown in FIG. 16that is an enlarged plan view of a part of the drawing surface 18,lyophilic areas 173 are disposed within the liquid repellent area 171.The liquid repellent area 171, as described above, is an area thatrepresents liquid repellency for the functional liquid 53. The lyophilicarea 173 is an area that represents a lyophillicity stronger than thatof the liquid repellent area 171 for the functional liquid 53.

In this embodiment, a plurality of the lyophilic areas 173 is disposed.The plurality of the lyophilic areas 173 are independently formed inisland shapes within the liquid repellent area 171. In FIG. 16, in orderto represent the configuration to be more easily understood, hatching isadded to the liquid repellent area 171.

In this embodiment, the plurality of the lyophilic areas 173 is arrangedin the X′ direction and the Y′ direction. The X′ direction and the Y′direction are directions intersecting each other and are not related tothe X direction or the Y direction in the molding apparatus 5. In thisembodiment, the X′ direction and the Y′ direction are perpendicular toeach other.

A plurality of the lyophilic areas 173 arranged in the Y′ directionconfigures a lyophilic column 175. A plurality of the lyophilic areas173 arranged in the X′ direction configures a lyophilic row 176.

A gap size Fx between the lyophilic areas 173 that are adjacent to eachother in the X′ direction is set to be equal to or less than 1.25 timesthe outer diameter of the liquid droplet 55. In addition, a gap size Fybetween the lyophilic areas 173 that are adjacent to each other in theY′ direction is set to be equal to or less than 1.25 times the outerdiameter of the liquid droplet 55.

First Embodiment

A method of forming the liquid repellent area 171 and the lyophilicareas 173 on the substrate Win the first embodiment will be described.

In the first embodiment, first, by coating the drawing surface 18 with amaterial containing a fluoroalkylsilane compound, a liquid repellentarea 174 shown in FIG. 17 is formed. At this time, the liquid repellentarea 174 includes a plurality of island-shaped areas 177. Theisland-shaped areas 177 are areas in which lyophilic areas 173 are to berespectively formed. In FIG. 17, in order to represent the configurationto be more easily understood, hatching is added to the liquid repellentarea 174.

Next, by destroying the liquid repellency of the plurality ofisland-shaped areas 177, a plurality of lyophilic areas 173 shown inFIG. 16 is formed. As a method of destroying the liquid repellency ofeach of the plurality of island-shaped areas 177, a method ofirradiation of ultraviolet light, a method of irradiation of laserbeams, or the like may be used. At this time, it is preferable thatultraviolet light having a wavelength shorter than 200 nm is used as theultraviolet light for irradiation. The reason for this is that thedestruction of the liquid repellent area 171 caused by being irradiatedwith the ultraviolet light 163 in the above-described transfer processS3 can be easily suppressed.

As a result, the liquid repellent area 171 including the plurality oflyophilic areas 173 therein is formed.

Second Embodiment

In a substrate W according to a second embodiment, as shown in FIG. 18that is a cross-sectional view taken along line D-D shown in FIG. 16, aplurality of lyophilic areas 173 protrude from the liquid repellentareas 171. In other words, in the substrate W according to the secondembodiment, a plurality of convex portions 178 is included. The topportion of each of the plurality of convex portions 178 is formed as thelyophilic area 173.

A method of manufacturing the substrate W according to the secondembodiment will now be described.

In the method of manufacturing the substrate W of the second embodiment,as shown in FIG. 19A, first, resist patterns 181 are patterned on asubstrate W′. The substrate W′ is a substrate that is the origin of thesubstrate W. The resist patterns 181 are disposed in positionscorresponding to the convex portions 178 (FIG. 18). The resist patterns181 can be patterned by using a spin coat technology, aphotolithographic technology, and the like.

After the patterning of the resist patterns 181, by etching thesubstrate W′, as shown in FIG. 19B, the plurality of convex portions 183is formed. The plurality of convex portions 183 protrudes from thesubstrate surface 184. The convex portions 183 are portions that becomeconvex portions 178.

Next, by coating the resist patterns 181 and the substrate W′ with amaterial containing a fluoroalkylsilane compound, as shown in FIG. 19C,a liquid repellent area 185 is formed on the substrate surface 184 andthe convex portion 183. The liquid repellent area 185 includes thesubstrate surface 184, the top portion of the convex portion 183, and aside portion of the convex portion 183.

Next, by polishing the top portions of the plurality of the convexportions 183 by using a CMP (Chemical Mechanical Polishing) method orthe like, a plurality of the convex portions 178 shown in FIG. 18 isformed.

Accordingly, the liquid repellent area 171 including a plurality of thelyophilic areas 173 therein is formed.

In this embodiment, a functional liquid 53 corresponds to a liquid, asubstrate W corresponds to a drawing stand, a transfer plate 85corresponds to a molding stand, and a transfer process S3 corresponds toapplying of activation energy and detaching of the cross-sectionpatterns. In addition, in the transfer process, the process of Step S53corresponds to the applying of activation energy, and the process ofStep S55 corresponds to the detaching of the cross-section patterns.

In addition, in each of the first embodiment and the second embodiment,the Y′ direction corresponds to a first direction, the X′ directioncorresponds to a second direction, a lyophilic column 175 corresponds toa first arrangement, and a lyophilic row 176 corresponds to a secondarrangement.

According to this embodiment, in the substrate W, the lyophilic areas173 are independently disposed in island shapes within the liquidrepellent area 171. Accordingly, when the drawing surface 18 is coatedwith the functional liquid 53, the functional liquid 53 can bemaintained more easily in the lyophilic areas 173. Accordingly, theprecision of the cross-section pattern at a time when the cross-sectionpattern is drawn on the liquid repellent area 171 with the functionalliquid 53 can be easily increased. As a result, the precision of athree-dimensional object 7 can be easily increased.

In addition, in this embodiment, in the substrate W, a gap size Fx, anda gap size Fy are respectively set to be equal to or less than 1.25times the outer diameter of a liquid droplet 55 ejected from theejection head 33. Accordingly, when a liquid droplet 55 lands on a spacebetween the lyophilic areas 173 adjacent to each other, a dot formed bythe landed liquid droplet 55 can be easily maintained in a gap betweenthe two lyophilic areas 173 that are adjacent to each other.Accordingly, the precision of the three-dimensional object 7 can befurther easily increased.

In addition, in each of the first embodiment and the second embodiment,a plurality of the lyophilic areas 173 is arranged on the substrate W inthe X′ direction and the Y′ direction. However, the arrangement of theplurality of the lyophilic areas 173 is not limited thereto. As thearrangement of the plurality of the lyophilic areas 173, for example, anarrangement in which a plurality of the lyophilic areas 173 is alignedin a zigzag pattern in the X′ direction, as shown in FIG. 20, may beused. The arrangement shown in FIG. 20 is also referred to as a zigzagarrangement.

In the zigzag arrangement shown in FIG. 20, a plurality of the lyophiliccolumns 175 is aligned in a zigzag pattern in the X′ direction. Inaddition, in the zigzag arrangement shown in FIG. 20, a plurality of thelyophilic columns 175 is aligned in the U direction. The U direction isa direction intersecting both the X′ direction and the Y's direction.

In the zigzag pattern shown in FIG. 20, a gap between two lyophilicareas 173 adjacent to each other in the U direction can be set to besmaller than that of the arrangement shown in FIG. 16. Accordingly, whena liquid droplet 55 lands on a space between the lyophilic areas 173adjacent to each other in the U direction, a dot formed by the landedliquid droplet 55 can be easily maintained in the gap between the twolyophilic areas 173 adjacent to each other. Accordingly, the precisionof the three-dimensional object 7 can be further easily increased.

In addition, in the zigzag pattern shown in FIG. 20, it is preferablethat a gap size Fu between the lyophilic areas 173 adjacent to eachother in the U direction is set to be equal to or less than 1.25 timesthe outer diameter of a liquid droplet 55. Accordingly, when a liquiddroplet 55 lands on a space between the lyophilic areas 173 adjacent toeach other in the U direction, a dot formed by the landed liquid droplet55 can be easily maintained in a gap between the two lyophilic areas 173that are adjacent to each other in the U direction. Accordingly, theprecision of the three-dimensional object 7 can be further easilyincreased.

In addition, in each of the first embodiment and the second embodiment,a plurality of the lyophilic areas 173 is arranged on the substrate W inthe X′ direction and the Y′ direction. However, the arrangement form ofthe plurality of the lyophilic areas 173 is not limited thereto. As thearrangement form of the plurality of the lyophilic areas 173, forexample, a form may be used in which the plurality of the lyophilicareas is arranged in a spiral shape using a Fibonacci sequence. TheFibonacci sequence is a numerical sequence configured by 1, 1, 2, 3, 5,8, 13, 21, 34, 55, 89, . . . . When this is represented in a recurrenceformula, the following Equation (1) is acquired.f ₁=1, f ₂=1, f _(i+2) =f _(i+1) +fi  (1)

When the angle of (f_(i−1))/(f_(i+1))×360 degrees is represented in anumerical sequence, the value of the angle gets closer to a golden angle(137.5078 . . . ) as the value of i increases.

In addition, on an X′Y′ plane defined by the X′ direction and the Y′direction, when the lyophilic area 173 is disposed at coordinates (x′,y′) calculated by using the following Equation (2), the plurality of thelyophilic areas 173 can be disposed in a spiral shape using a Fibonaccisequence.x′r×cos(θ×i), y′=r×sin(θ×i)  (2)

In Equation (2), θ is the value (137.5078 . . . ) of the golden angle.In addition, i is an integer equal to or higher than one. In addition, ris represented by the following Equation (3).r=a×√(i)  (3)

In Equation (3), a is a proportional constant and an arbitrary numbergreater than zero.

In the form in which a plurality of the lyophilic areas 173 is disposedin a spiral shape by using the above-described Fibonacci sequence, in aplurality of the lyophilic areas 173 overlapping an arbitrary straightline on the X′Y′ plane, the regularity of the gaps between the lyophilicareas 173 adjacent to each other can be easily excluded. In other words,in the form in which a plurality of the lyophilic areas 173 is disposedin a spiral shape by using the above-described Fibonacci sequence, in aplurality of the lyophilic areas 173 overlapping an arbitrary straightline on the X′Y′ plane, gaps between the lyophilic areas 173 adjacent toeach other can be set to be irregular.

As a result, in the drawing process S2, even when a plurality of liquiddroplets 55 regularly lands on the substrate W, generation of regularknurling shapes (jaggy shapes) in the cross-section pattern 165 can beeasily suppressed to the low level due to irregularity of the pluralityof the lyophilic areas 173.

In addition, also in this embodiment, in the drawing process S2, as amethod of coating the functional liquid 53, an ink jet method that isone of the coating methods is used. However, the coating method is notlimited to the ink jet method, and a dispensing method, a printingmethod, or the like may be used. However, it is preferable to use theink jet method from the viewpoint that an arbitrary spot on thesubstrate W can be easily coated with a functional liquid 53 of anarbitrary amount.

In this embodiment, five types of color coating materials includingyellow, magenta, cyan, black, and white are used. However, the colors ofthe color coating materials are not limited thereto. As the colors ofthe color coating materials, for example, one or more arbitrary types ofcolor coating materials such as seven types acquired by adding lightcyan and light magenta or the like to the above-described five types canbe used.

In this embodiment, as activation energy that is used for precipitatingthe curing of the functional liquid 53, light is used. However, theactivation energy is not limited thereto, and, for example, heat may beused. In other words, as the functional liquid 53, a functional liquid53 having a thermosetting property that is a property, in which curingis precipitated in accordance with reception of heat, may be used.

In addition, in this embodiment, the configuration in which the moldingapparatus 5 includes the substrate W is shown as an example. However,the configuration of the molding apparatus 5 is not limited thereto. Asthe configuration of the molding apparatus 5, for example, aconfiguration in which the substrate W is omitted may be used. In such aconfiguration, the cross-section pattern 165 is drawn on the table 25.Accordingly, in this configuration, the mounting surface 25 acorresponds to a drawing surface 18. In addition, in the moldingapparatus 5 that does not include the substrate W, the table 25corresponds to a drawing stand.

What is claimed is:
 1. A molding method comprising: dividing athree-dimensional object as a molding target into a plurality ofcross-section elements and drawing the cross-section elements ascross-section patterns on a drawing surface of a drawing stand, thedrawing surface having a liquid whose curing is precipitated byreceiving activation energy; applying the activation energy to theliquid configuring the cross-section patterns in a state in which thecross-section patterns drawn on the drawing stand is pinched between thedrawing stand and a molding stand; and detaching the cross-sectionpatterns after being applied with the activation energy from the drawingstand and transferring the cross-section patterns to the molding stand,wherein, in the dividing of the three-dimensional object and the drawingof the cross-section elements, the cross-section patterns are drawn onthe drawing surface that has a liquid repellent area that has liquidrepellency for the liquid, the drawing surface has a plurality oflyophilic areas that are independently formed in an island shape with agap between the plurality of lyophilic areas within the liquid repellentarea, a lyophilicity of each of the plurality of lyophilic areas islarger than a lyophilicity of the liquid repellent area, and in thedrawing the cross-section elements as the cross-section patterns, thecross-section patterns are maintained in the gap between the pluralityof lyophilic areas.
 2. The molding method according to claim 1, whereinthe liquid has photo curability that is a property of being precipitatedto be cured by receiving irradiation of light, and wherein, in theapplying of the activation energy, the liquid is irradiated with thelight.
 3. The molding method according to claim 1, wherein, in thedividing of the three-dimensional object and the drawing of thecross-section elements, the cross-section patterns are drawn on thedrawing surface by ejecting the liquid to the drawing stand using an inkjet method.